Fixation device for a portable orbital drilling unit

ABSTRACT

A fixation device for positioning a rotating machine tool onto a template, the template having at least one hole and at least one locating pin. The fixation device includes a housing with a housing tool end and a housing template end, a seat located on the housing tool end for coupling with the rotating machine tool, and a clamping mechanism disposed at least partially at the housing template end for coupling with at least one locating pin.

BACKGROUND OF THE INVENTION CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This is a non-provisional application based upon U.S. provisional patent application serial No. 60/299,007, entitled “FIXATION DEVICE FOR A PORTABLE ORBITAL DRILLING UNIT”, filed Jun. 18, 2001.

[0002] 1. Field of the Invention

[0003] The present invention relates to a fixation device for mounting a hand tool to a drill template when cutting a hole in an object, and, more particularly, a fixation device used with a drill template and a hand tool for cutting a hole that has a larger diameter than the diameter of the cutting tool.

[0004] 2. Description of the Related Art

[0005] When machining materials using a portable or hand tool, many advantages are achieved due to the flexible positioning of the tool and degrees of freedom of motion of the tool with respect to the workpiece. The advantages of using a portable or hand tool include the ability to position the tool in positions not allowed by a stationary tool, overhead for example, or to position the tool and machine a workpiece that is part of a larger assembly, such as may occur during a repair operation. Machining a workpiece with a curved (or other non flat geometry) surface can be made easier with a portable or hand tool due to the inherent positioning flexibility.

[0006] Additionally, templates are used in conjunction with machine tools to easily replicate a workpiece pattern. When using templates the machine tool is guided by the template pattern requiring the motion of the machine tool to be constrained by the template pattern. The use of a template with a portable or hand tool can be problematic due to the inherent positioning flexibility and degrees of freedom of motion of the tool which now must be constrained to follow the template pattern.

[0007] U.S. Pat. No. 5,641,252 (Eriksson et al.) discloses a method for machining holes in a fiber reinforced composite material by using at least one cutting tool with wear resistant surface positioned eccentrically in relation to a central axis. The material is machined simultaneously in both an axial and a radial direction by causing the tool to move axially while rotating not only about its own axis, but also eccentrically about the central axis. In accordance with one feature of the invention, the workpiece is oriented in such a way that the axis of rotation of the tool is essentially orthogonal in relation to the longitudinal directions of the fibers in the immediate vicinity of the point where the tool meets the working surface. The diameter of the cutting tool is substantially smaller than the diameter of the hole that is produced. The eccentric rotary motion is generally a strictly rotary motion, i.e., it is executed with a constant distance between the central axis and the axis of rotation of the cutting tool. This distance between the central axis and the axis of rotation of the cutting tool can be increased by linear increments as the eccentric rotary motion continues.

[0008] This known method has a number of substantial advantages as compared with generally familiar techniques. For example, the method permits the production of holes without strength reducing damage. Also, the method permits the production of holes free from damage without having to preform a hole. Further, the method permits the production of holes to tight tolerances. The dimensional accuracy of the hole is determined substantially by the accuracy of the positioning of the tool relative to the central axis. The requirements imposed on the geometry of the cutting tool are not particularly high, on the other hand, since every individual tool is simply calibrated before use. Additionally, the method prevents the tool from becoming blocked. Since the diameter of the tool is substantially smaller than that of the hole, the method permits material removed by cutting to be carried away by simple means, such as with compressed air. The method also permits effective cooling of the tool and the edge of the hole. Yet another advantage is that the method substantially reduces the cost of wear compared to previously disclosed methods, due to the tool being coated with a wear resistant material, such as diamond coating. Moreover, this method also offers advantages when machining other materials such as metals.

[0009] U.S. Pat. No. 6,382,890 (Linderholm) discloses a hand tool apparatus using a cutting tool to machine a hole in an object such that the hole has a width at least as large as the width of the cutting tool. The center line of the hole passes through a predetermined point on the surface of the object. Moreover, the disclosed invention provides a compact and lightweight hand tool apparatus for machining holes in a flat or curved object of any material by rotating a cutting tool about its own axis and about a principal axis while simultaneously feeding in the axial direction. A lightweight and compact apparatus is achieved by integrating a radial offset mechanism, spindle motor and axial feed mechanism in a same actuating assembly package, which rotates about a principal axis.

[0010] Template machining is well known in the art when using a machine tool to replicate an object or pattern in a workpiece. A template is used to consistently guide a machine tool during the machining operation and thereby simplify the process. A hand tool apparatus as disclosed in U.S. Pat. No. 6,382,890 (Linderholm) has advantages over a fixed machine tool in terms of flexibility and more degrees of freedom in motion and positioning; however, these same advantages can create difficulty in maintaining the proper orientation of the hand tool apparatus with respect to the template and workpiece during the machining operation. This difficulty may be particularly evident during an orbital drilling process when the tool is subjected to both an axial force and a radial force through the cutting tool tip by virtue of machining simultaneously in both an axial and radial direction.

[0011] What is needed in the art is a method and device for maintaining the orientation of a hand tool apparatus with respect to the template and during the machining process.

SUMMARY OF THE INVENTION

[0012] The present invention provides a method and device for fixing the orientation of a rotating machine tool with respect to a machining template.

[0013] The invention comprises, in one form thereof, a fixation device for positioning a rotating machine tool onto a template, the template having at least one hole and at least one locating pin. The fixation device includes a housing with a housing tool end and a housing template end, a seat located on the housing tool end for coupling with the rotating machine tool, and a clamping mechanism disposed at least partially at the housing template end for coupling with at least one locating pin.

[0014] An advantage of the present invention is that the fixation device maintains the orientation of a rotating machine tool with respect to the workpiece during the machining process.

[0015] Another advantage of the present invention is that the fixation device is easily released from the template.

[0016] Yet another advantage of the present invention is the ability of the fixation device to remove and exhaust machining debris from the machining area during the machining process.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:

[0018]FIG. 1 is perspective view of an embodiment of a fixation device of the present invention with a rotating machine tool mounted therein and shown clamped to a machining template with workpiece;

[0019]FIG. 2 is a sectional view taken along section line 2-2 in FIG. 1 showing only an embodiment of the fixation device, a machining template and a workpiece;

[0020]FIG. 3 is perspective view of another embodiment of a fixation device of the present invention with a rotating machine tool mounted therein and shown clamped to a machining template with workpiece; and

[0021]FIG. 4 is a sectional view taken along section line 4-4 in FIG. 3 showing only an embodiment of the clamping mechanism of the fixation device fixed to a single locating pin, a rotating machine tool mounted therein, a machining template and a workpiece.

[0022] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE INVENTION

[0023] Referring now to the drawings, and more particularly to FIG. 1, there is shown a fixation device 10 of the present invention with a rotating machine tool 12 mounted on and therein and shown clamped to a machining template 14 with workpiece 16.

[0024] Workpiece 16 may be made of a composite material, such as a fiber-reinforced composite material, or alternatively, may be of metal composition including alloys or a combined metal and composite makeup. Workpiece 16 may be flat or have curved surfaces or other surface geometries. Machining area 64 in workpiece 16 may be a hole or other geometries as dictated by workpiece 16 form, fit, function and/or design.

[0025] Rotating machine tool 12 is shown as a portable orbital drilling unit; alternatively, rotating machine tool 12 can be a grinding tool, a milling tool or a boring tool.

[0026] Template 14 includes at least one hole 18 and at least one locating pin 20. Hole 18 may be circular or other geometries as required by workpiece 16 machining area 64 form, fit, function and/or design. Locating pin 20 is shown having an hourglass shape with annular ring 60 proximate to locating pin 20 center; alternatively, locating pin 20 may have other shapes such as T shaped or the shape of an inverted L. For each hole 18 in template 14 there is at least one locating pin 20 mounted proximate thereto.

[0027] Fixation device 10 (FIG. 2) generally includes housing 22, seat 24 and clamping mechanism 26. Seat 24 is disposed on housing tool end 28 of housing 22. Seat 24 interfaces between rotating machine tool 12 and housing 22 and provides mounting for rotating machine tool 12.

[0028] Clamping mechanism 26 includes piston 32, clamping actuator 40, unclamping actuator 52, ball holder 54, pressure cylinder 56 and releasable ball 58. Piston 32 is located within housing 22 and includes piston flange 34 on piston actuating end 36. Clamping actuator 40, shown in FIG. 2 as a resilient member or spring, normally forces piston 32 towards housing template end 30 by acting upon piston flange 34.

[0029] Air coupling 42 connects pressure dispersion area 44 to a source of compressed gas (not shown). Piston seal 46 and first seal 48 in conjunction with piston 32 and housing 22, when connected to a source of compressed gas through air coupling 42, allow a positive pressure (with respect to atmospheric pressure) to build in pressure dispersion area 44, and this positive pressure acts on piston flange 34 and counteracts the force of clamping actuator 40. Air evacuation hole 50 in housing 22 is operatively coupled to pressure dispersion area 44 to ensure that the positive pressure does not bind piston 32 against housing 22. In one embodiment, pressure dispersion area 44 is defined by the space bounded by piston 32, housing 22, piston seal 46 and first seal 48.

[0030] In the absence of a sufficient positive pressure in pressure dispersion area 44, clamping actuator 40 will force piston 32 towards housing template end 30. When so actuated, pressure cylinder 56 connected to piston clamping end 38, supported by ball holder 54 and disposed at least partially at the housing template end 30, engages at least one locating pin 20 of template 14 by pushing releasable ball 58 into annular ring 60 of locating pin 20. Fixation device 10 is thus clamped to template 14.

[0031] Unclamping actuator 52 is a pneumatic system having air coupling 42 operatively coupled to pressure dispersion area 44 and an air evacuation hole 50 in housing 22 coupled to pressure dispersion area 44. To unclamp fixation device 10 from template 14 compressed gas is introduced at air coupling 42 creating a positive pressure in pressure dispersion area 44. This positive pressure acts on piston flange 34 and counteracts the force of clamping actuator 40, allowing piston 32 to disengage releasable ball 58 from annular ring 60. Fixation device 10 may then be moved from template 14.

[0032] Exhaust system 62 can be optionally provided to remove debris from machining area 64. Exhaust system 62 includes bellows 66 located at housing template end 30, vacuum exhaust 68 interposed between piston 32 and housing tool end 28, and second seal 70 between piston 32 and vacuum exhaust 68. After clamping fixation device 10 to template 14, bellows 66 seals machining area 64. Attaching a vacuum source (not shown) to vacuum exhaust 68 removes debris from machining area 64.

[0033] To operate fixation device 10 during a machining operation, template 14 is positioned on workpiece 16, and fixed in place, if necessary, by common elements known in the art such as a C clamp. Fixation device 10 is then located proximate to at least one hole 18 and at least one locating pin 20 and clamped to template 14 by disconnecting a source of compressed gas at air coupling 42 or disconnection of the source of compressed gas at air coupling 42 by other common elements such as a switch. Disconnection of the source of compressed gas will simultaneously disable unclamping actuator 52 and enable clamping actuator 40 thus clamping fixation device 10 to template 14. Rotating machine tool 12 is mounted on seat 24 and through housing 22 and hole 18 to engage and machine workpiece 16 at machining area 64.

[0034] In another embodiment (FIGS. 3 and 4), fixation device 12 is clamped to a single locating pin 20. In this embodiment, locating pin 20 has aperture 72 through which rotating machine tool 12 is positioned to access machining area 64. Locating pin 20 is located such that aperture 72 is roughly concentric with hole 18 and machining area 64. Clamping and unclamping fixation device 12 occurs as described previously, wherein pressure cylinder 56 connected to piston clamping end 38, supported by ball holder 54 and disposed at least partially at the housing template end 30, engages or disengages locating pin 20 of template 14 by pushing at least one releasable ball 58 into annular ring 60 of locating pin 20.

[0035] While this invention has been described as having a preferred design, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. 

What is claimed is:
 1. A fixation device for positioning a rotating machine tool onto a template, the template having at least one hole and at least one locating pin, said fixation device comprising: a housing with a housing tool end and a housing template end; a seat located on said housing tool end for coupling with the rotating machine tool; and a clamping mechanism disposed at least partially at said housing template end for coupling with at least one locating pin.
 2. The fixation device of claim 1, wherein said clamping mechanism includes a piston located within said housing, said piston having a piston actuating end and a piston clamping end, said piston actuating end proximate to housing tool end, said piston clamping end proximate to housing template end.
 3. The fixation device of claim 2, wherein said clamping mechanism further includes a clamping actuator coupling said piston actuating end and said housing tool end.
 4. The fixation device of claim 3, wherein said clamping actuator is a resilient member.
 5. The fixation device of claim 4, wherein said resilient member is a spring.
 6. The fixation device of claim 2, wherein said clamping mechanism further includes an unclamping actuator coupling said piston actuating end and said housing tool end.
 7. The fixation device of claim 6, wherein said unclamping actuator is a pneumatic system.
 8. The fixation device of claim 1, wherein said clamping mechanism includes a piston, a pneumatic system having an air coupling operatively coupled to a pressure dispersion area, a first seal located between said piston and said housing and towards said housing template end, a piston seal located between said piston and said housing and towards said housing tool end, said pressure dispersion area bounded by said first seal, said piston, said housing and said piston seal, and an air evacuation hole in said housing coupled to said pressure dispersion area.
 9. The fixation device of claim 1, further including an exhaust system.
 10. The fixation device of claim 1, wherein said clamping mechanism further includes a piston located within said housing, said fixation device includes an exhaust system having a bellows located at said housing template end, a vacuum exhaust interposed between said housing tool end and said bellows and a second seal interposed between said piston and said vacuum exhaust.
 11. The fixation device of claim 1, wherein said clamping mechanism includes a piston located within said housing, said piston having a piston actuating end and a piston clamping end, a clamping actuator coupling said piston actuating end and said housing tool end, an unclamping actuator coupling said piston actuating end and said housing tool end, at least one ball holder, a pressure cylinder disposed on said piston clamping end and supported by at least one said ball holder and at least one releasable ball located in at least one said ball holder, at least one locating pin includes an annular ring wherein at least one said releasable ball engages during actuation of said clamping actuator and disengages during actuation of said unclamping actuator.
 12. The fixation device of claim 1, wherein the rotating machine tool includes a portable orbital drilling unit.
 13. The fixation device of claim 1, wherein the rotating machine tool includes a grinding tool.
 14. The fixation device of claim 1, wherein the rotating machine tool includes a milling tool.
 15. The fixation device of claim 1, wherein the rotating machine tool includes a boring tool.
 16. A machine tool system for removing material in a workpiece, said machine tool system comprising: a rotating machine tool; a template including at least one hole and at least one locating pin; and a fixation device including: a housing with a housing tool end and a housing template end; a seat located on said housing tool end for coupling with the rotating machine tool; and a clamping mechanism disposed at least partially at said housing template end for coupling with at least one said locating pin.
 17. The fixation device of claim 16, wherein said clamping mechanism includes a piston located within said housing, said piston having a piston actuating end and a piston clamping end, said piston actuating end proximate to housing tool end, said piston clamping end proximate to housing template end.
 18. The fixation device of claim 17, wherein said clamping mechanism further includes a clamping actuator coupling said piston actuating end and said housing tool end.
 19. The fixation device of claim 18, wherein said clamping actuator is a resilient member.
 20. The fixation device of claim 19, wherein said resilient member is a spring.
 21. The fixation device of claim 17, wherein said clamping mechanism further includes an unclamping actuator coupling said piston actuating end and said housing tool end.
 22. The fixation device of claim 21, wherein said unclamping actuator is a pneumatic system.
 23. The fixation device of claim 16, wherein said clamping mechanism includes a piston, a pneumatic system having an air coupling operatively coupled to a pressure dispersion area, a first seal located between said piston and said housing and towards said housing template end, a piston seal located between said piston and said housing and towards said housing tool end, said pressure dispersion area bounded by said first seal, said piston, said housing and said piston seal, and an air evacuation hole in said housing coupled to said pressure dispersion area.
 24. The fixation device of claim 16, further including an exhaust system.
 25. The fixation device of claim 16, wherein said clamping mechanism further includes a piston located within said housing, said fixation device includes an exhaust system having a bellows located at said housing template end, a vacuum exhaust interposed between said housing tool end and said bellows and a second seal interposed between said piston and said vacuum exhaust.
 26. The fixation device of claim 16, wherein said clamping mechanism includes a piston located within said housing, said piston having a piston actuating end and a piston clamping end, a clamping actuator coupling said piston actuating end and said housing tool end, an unclamping actuator coupling said piston actuating end and said housing tool end, at least one ball holder, a pressure cylinder disposed on said piston clamping end and supported by at least one said ball holder and at least one releasable ball located in at least one said ball holder, at least one locating pin includes an annular ring wherein at least one said releasable ball engages during actuation of said clamping actuator and disengages during actuation of said unclamping actuator.
 27. The machine tool system of claim 16, wherein said rotating machine tool includes a portable orbital drilling unit.
 28. The machine tool system of claim 16, wherein said rotating machine tool includes a grinding tool.
 29. The machine tool system of claim 16, wherein said rotating machine tool includes a milling tool.
 30. The machine tool system of claim 16, wherein said rotating machine tool includes a boring tool.
 31. A method of removing material in a workpiece using a rotating machine tool, comprising the steps of: positioning a template including at least one hole and at least one locating pin on the workpiece; locating a fixation device proximate to at least one said hole and at least on said locating pin; clamping said fixation device to said template, said fixation device including a housing with a housing tool end and a housing template end, a seat located on said housing tool end, and a clamping mechanism disposed at least partially at said housing template end for coupling with at least one said locating pin; mounting the rotating machine tool on said seat; and machining a machining area in the workpiece by actuating the rotating machine tool through said hole and within said fixation device.
 32. The method of claim 31, further including the step of unclamping said fixation device following said machining step.
 33. The method of claim 32, wherein said unclamping step includes operatively coupling said fixation device to a source of compressed gas.
 34. The method of claim 32, wherein said unclamping step includes decoupling at least one releasable ball from at least one said locating pin.
 35. The method of claim 31, wherein said clamping step includes coupling at least one releasable ball to at least one said locating pin.
 36. The method of claim 31, further including the step of exhausting said machining area during said machining step. 